Method and apparatus for winding/unwinding cable

ABSTRACT

An apparatus, assembly and method for winding elongate material onto a flanged reel, or unwinding material from a flanged reel. The apparatus includes a linear powered drive shaft and a substantially helical drive pin. The drive pin is utilized to rotate a flanged reel about the drive shaft, and the helical shape of the drive pin causes the reel to be urged onto the drive shaft thereby preventing unwanted displacement of the reel from the drive shaft. To this end, the tension of the material being wound onto, or unwound from, the reel generates a torque on the reel to cause it to screw onto the drive pin as a nut screws onto a bolt.

FIELD OF THE INVENTION

[0001] The present invention relates to winding and unwinding cable, wire and the like onto and off of flanged reels, and more particularly, the present invention relates to an apparatus and method for efficiently winding/unwinding cable relative to a flanged reel which is rotatably supported on a powered drive shaft.

BACKGROUND OF THE INVENTION

[0002] U.S. Pat. No. 5,332,166 issued to Kepes discloses a method and apparatus for winding cable onto flanged reels. In the background section of the Kepes patent, a commercially available cable winding apparatus is disclosed. To this end, the prior art apparatus is stated as having an arm with a spindle for rotatably supporting a flanged reel by its longitudinally-extending central opening. A linear drive pin extends parallel to the arm and engages a recess which is located on one of the flanges of the reel and which is spaced radially outward from the central opening. Thus, when the linear drive pin is rotated in a circular path about an axis extending through the arm, the reel is rotated in a desired direction.

[0003] U.S. Pat. Nos. 4,436,249 issued to Santa Lucia et al., 1,865,236 issued to Daniels, and 2,141,395 issued to Johnston et al. disclose cable winding apparatus which utilize drive pins to rotate reels in a desired direction. Each discloses the use of a linear drive pin which extends in a direction parallel to a shaft on which the reel is rotatably supported.

[0004] As stated in the Kepes patent, such an apparatus has a disadvantage in that the installation of the reel on the support arm requires a manual operation of pre-positioning the reel onto the support arm such that the recess and drive pin are fully engaged. As stated, such an operation is particularly labor-intensive when dealing with heavy reels capable of containing relatively long lengths of heavy duty cable, wire, or like flaccid material.

[0005] Further, such apparatus requires the placement of a clamp collar on the outer free end of the drive shaft to safely lock the flanged reel on the drive shaft and to prevent it from becoming unwantedly displaced off the drive shaft during a winding or unwinding operation. The unwanted ejection of a flanged reel from the drive shaft during rotation of the flanged reel could potentially cause serious damage to the operator and equipment. Thus, the use of the clamp collar is necessary for safety reasons, and the time and manual labor required to secure and remove the clamp collar has been unavoidable.

[0006] Other known cable winding apparatus are disclosed in U.S. Pat. Nos. 3,948,462 issued to Maillefer, 3,837,589 issued Johnson et al, 3,841,575 issued Pepe et al., 4,664,325 issued to Pepe, and 4,792,100 issued to Pepe.

[0007] While the aforementioned apparatus and methods for winding cable may be satisfactory for their intended purposes, there is a need for an apparatus and method for use in efficiently winding cable onto flange reels in a minimum of time requiring only a minimum of manual labor. To this end, the use of a clamp collar or other locking device on the free end of the powered drive shaft should be eliminated. However, the apparatus should be capable of being operated safely in a reliable manner. In addition, preferably the loading of flanged reels onto the drive shaft and/or removal of flanged reels off of the drive shaft should be simplified so that such tasks are capable of being semi or fully automated thereby further enhancing the efficiency of the winding operation. Further, the apparatus and method should also be useful in unwinding cable from flanged reels.

OBJECTS OF THE INVENTION

[0008] With the foregoing in mind, a primary object of the present invention is to provide an apparatus for efficiently winding cable onto, or unwinding cable from, a flanged reel.

[0009] Another object of the present invention is to provide a method for efficiently winding cable onto, or unwinding cable from, a flanged reel.

[0010] A further object of the present invention is to simply the process of loading and unloading a flanged reel onto a powered drive shaft such that the loading/unloading process may be semi or fully automated.

[0011] A still further object of the present invention is to provide a method and apparatus for safely and reliably rotating a flanged reel on a powered drive in a manner which prevents unwanted displacement of the flanged reel from the drive shaft.

SUMMARY OF THE INVENTION

[0012] More specifically, the present invention is an apparatus for winding/unwinding cable, wire, chain or like material onto, or off, a flanged reel. The apparatus includes a linear drive shaft and a non-linear drive pin which extends in a direction transverse and non-parallel of the drive shaft. Thus, when the flanged reel is supported on the shaft and is engaged by the drive pin and when the drive pin is rotated about an axis extending through the drive shaft, the reel rotates and the tension of the cable being wound onto the reel generates a torque on the flanged reel to cause the flange reel to become further engaged with the drive pin. This causes the flange reel to be slidable urged further onto the drive shaft and prevents the flanged reel from being displaced from the drive pin and drive shaft during a winding, or unwinding, operation.

[0013] Preferably, the drive pin has a helical shape which at least partially wraps about the drive shaft a spaced radial distance from the drive shaft. Thus, the tension of the cable causes the flanged reel to be screwed onto the drive pin during the winding or unwinding operation. In addition, preferably the drive shaft and helical drive pin extend from, and are interconnected by, a hub, and preferably, rotation of the hub, drive shaft, and drive pin is powered by a motor.

[0014] According to another aspect of the present invention, an assembly for winding/unwinding cable, wire or the like is provided. The assembly includes a linear powered drive shaft which defines an axis of rotation and a flanged reel which is slidably supported on the drive shaft for rotation about the axis of rotation. The flanged reel has an inboard flange which is received on the drive shaft, extends transversely therefrom, and has a drive pin receiving channel. The apparatus includes a non-linear drive pin which is rotatable about the axis of rotation and which extends in a direction non-parallel and transverse of the drive shaft. The drive pin receiving channel can have a cylindrical shape such that it extends parallel to the axis of rotation, or alternatively, the channel can have a non-linear shape that corresponds to the non-linear shape of the drive pin. Thus, when the tip of the drive pin extends completely through a cylindrical channel or when the tip of the drive pin extends at least partially into a non-linear channel, the drive pin causes the flanged reel to be rotated about the axis and a torque is generated on the flanged reel by the tension of the cable being wound/unwound to urge the flanged reel into further engagement with the drive pin and in a direction onto the drive shaft thereby preventing the flanged reel from being displaced from the drive shaft toward the free end of the drive shaft.

[0015] Preferably, at least a portion of the drive pin has a helical shape which at least partially wraps about the drive shaft a spaced distance from the drive shaft. In addition, the drive shaft rotates in a pre-determined direction of rotation about the axis, the helical-shaped portion of the drive pin includes at least a tip of the drive pin, and, when the assembly is utilized to wind cable onto the flanged reel, the tip wraps about the drive shaft in a direction corresponding to the pre-determined direction of rotation of the drive shaft. Alternatively, when the assembly is utilized to unwind cable from a flanged reel, the helical tip wraps about the drive shaft in a direction corresponding to opposite that of the pre-determined direction of rotation of the drive shaft.

[0016] Yet another concept according to the present invention relates to a method of winding/unwinding cable, wire or the like onto or off of a flanged reel. To this end, a flanged reel is slidably engaged axially on a linear drive shaft which extends from a hub. The flanged reel has an inboard flange relative to the hub, and the inboard flange has a drive pin receiving channel. A tip of a non-linear drive pin which extends from the hub is engaged in the channel of the inboard flange. The non-linear drive pin rotates the flanged reel about an axis extending through the linear drive shaft to perform either a winding, or unwinding, operation. During the operation, the tension of the cable generates a torque on the flanged reel causing it to advance onto the non-linear drive pin and urge the flanged reel in a direction toward the hub thereby preventing the flanged reel from being displaced from the drive shaft.

[0017] Preferably, the method includes a step of removing the flanged reel from the drive shaft after the flanged reel is rotated on the drive shaft. The free end of the drive shaft remains free during the rotating process step to permit prompt removal of the flanged reel from the drive shaft. In addition, preferably the steps of sliding the flanged reel onto the drive shaft and removing the flanged reel from the drive shaft are accomplished by semi or fully automated mechanisms.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The foregoing and other objects, features and advantages of the present invention should become apparent from the following description when taken in conjunction with the accompanying drawings, in which:

[0019]FIG. 1 is an exploded perspective view of an assembly including a flanged reel and a drive shaft and pin according to the present invention;

[0020]FIG. 2 is an elevational view of a flanged reel shown in broken lines supported on a winding/unwinding apparatus according to the present invention;

[0021]FIG. 3 is a cross-sectional view of the drive shaft and helical drive pin illustrated in FIG. 1 along line 3—3; and

[0022]FIG. 4 is a cross-sectional view of the drive shaft and helical drive pin illustrated in FIG. 1 along line 4—4.

DETAILED DESCRIPTION OF THE PREFERRED APPARATUS

[0023] The present invention primarily relates to winding elongate material onto a flanged reel 10 in a manner in which powered rotation of the flanged reel 10 causes the material to be pulled onto the reel 10. In addition, the present invention also relates to unwinding material from a flanged reel.

[0024] As best illustrated in FIGS. 1 and 2, the flanged reel 10 provides a means for storing and shipping elongate material of various sizes from a manufacturer to an end user. For purposes of this application, the term “elongate material” includes flaccid material, such as wire, cable, conduit, hose, terminal strips, paper, filler, fiber-optics, rope, yarn and metal strips, and non-flaccid material such as chains and the like.

[0025] The reel 10 includes a substantially cylindrical drum 12 extending between a pair of end flanges 14. To facilitate winding and unwinding of elongate material (not shown) on and off the drum 12, the reel 10 has a central passageway 16 extending along an axis “A” through the drum 12 and both end flanges 14. As best illustrated in FIG. 1, at least one of the flanges 14 includes a drive pin receiving aperture, or channel, 18 spaced a pre-determined distance from the central passageway 16. As illustrated, the channel 18 is cylindrical and extends parallel to axis “A”. Alternatively, the channel 18 can have other cross-sectional shapes, such as trapezoidal, and can extend in non-linear and/or transverse directions relative to axis “A”.

[0026] During a winding or unwinding operation, the flanged reel 10 is rotatably supported on a winding/unwinding apparatus 20 which includes a drive shaft 22 having a free end 22 a onto which the reel 10 can be supported. To this end, the reel 10 is slidably received on the drive shaft 22 such that the drive shaft 22 extends within the central passageway 16 of the flanged reel 10. Thereafter, the reel 10 can be rotated in a clockwise direction R₁, or a counterclockwise direction R₂, about axis “A” which extends longitudinally through the drive shaft 22. Rotation of the reel 10 causes cable to be pulled onto the reel 10. Alternatively, cable can be pulled and unwound from the reel 10 in which the pulling force causes the reel to rotate.

[0027] In a winding operation, the reel 10 is caused to rotate about the drive shaft 22 under the force of a drive pin 24 which revolves in a circular path about the drive shaft 22 and about axis “A”. The drive pin 24 mates within the aperture, or channel, 18 formed on the inboard flange 14, and causes the flanged reel 10 to be rotated about axis “A” when the drive pin 24 is rotated about axis “A”. Preferably, the diameter of the channel 18 is significantly larger than the diameter of the drive pin, as illustrated. Alternatively, the diameters can be sized to provide for a snug fit. Preferably, the drive shaft 22 rotates along with the drive pin 24, and preferably rotation is powered by a motor (not shown).

[0028] The novel concept of the present invention is that the drive pin 24 has a substantially helical shape and wraps at least partially about the drive shaft 22. To this end, the drive shaft 22 and drive pin 24 extend outwardly from a hub 26. The drive shaft 22 is linear, while the drive pin 24 is non-linear and extends in a direction transverse (ie., non-parallel) to that of the linear drive shaft 22. Preferably, as the drive pin 24 extends along its length from the hub 26, it is spaced a constant radial distance “B” from the drive shaft 22. The distance of the spacing “B” between the drive shaft 22 and the drive pin 24 matches the spacing of the aperture 18 from the drive shaft 22 so that the aperture 18 on the flange 14 can receive the drive pin 24 throughout substantially the entire length of the drive pin 24. Alternatively, the spacing “B” can be eliminated so that the drive pin 24 and channel 18 extend adjacent to the drive shaft 24.

[0029] As shown in the drawings, the drive pin 24 is not required to completely wrap about the drive shaft 22. By way of example, and not by way of limitation, the drive pin 24 can extend in a range between about one-eighth the distance around the drive shaft 22 to about one-quarter the distance around the drive shaft 22. For instance, see FIG. 3.

[0030] In use, the flanged reel 10 is slid onto the drive shaft 22 via the free end 22 a of the drive shaft 22, and the tip 24 a of the drive pin 24 is aligned with the channel 18 in the flange 14 of the flanged reel 10. If the channel 18 is cylindrical and extends parallel to the drive shaft, then the tip 24 a of the drive pin 24 must be extended completely through the channel. Alternatively, if the channel 18 is of a non-linear, or helical, shape which corresponds to that of the drive pin 24, the tip 24 a needs only be inserted partially through the channel 18. Thus, one advantage of the present invention is that the reel 10 is not required to be loaded onto the drive shaft 22 such that the entire drive pin is extended through the aperture 18 in the inboard flange 14.

[0031] The free end of the cable is then secured to the reel 10, and when the drive pin 24 is revolved about the drive shaft 22, the drive pin 24 causes the flanged reel 10 to be rotated about axis “A” in a direction of rotation corresponding to the direction of rotation of the drive pin 24. In turn, as the cable is wound (ie., pulled) onto the reel 10, the tension of the cable generates a torque on the flanged reel 10 to cause the flanged reel 10 to slidably advance on the drive shaft 22 in a direction toward the hub 26. To this end, the torque is sufficient in strength to overcome the frictional forces between the apparatus 20 and the reel 10 and causes the flange 14 to slide relative to the drive shaft 22 and to screw onto the drive pin 24 much like a nut screws onto a bolt. Thus, the flanged reel 10 is urged in a direction on the drive shaft 22 toward the hub 26 and away from the free end 22 a of the drive shaft 22 thereby preventing the flanged reel 10 from being unwantedly displaced off of the drive shaft 22 and eliminating the need to lock the reel 10 onto the drive shaft 22 with a clamp collar or like locking device. The same result can be achieved with apparatus 20 when utilized in an unwinding operation.

[0032] The direction in which the helical drive pin 24 wraps about the drive shaft 22 depends on the intended direction of rotation of the reel 10 about axis “A” and whether the cable is being wound onto, or unwound from, the reel 10. For example, if cable is being wound onto the reel 10 illustrated in FIG. 3, the direction of rotation of the reel is “R₁” (ie., clockwise in the drawing) to generate the torque necessary to advance the reel toward the hub. Thus, in this instance, the drive pin 24 would wrap about the drive shaft 22 in a direction corresponding with the direction of rotation “R₁” of the reel 10 on the drive shaft 22. Alternatively, if cable is being unwound from the reel 10 illustrated in FIG. 3, the direction of rotation of the reel is “R₂” (ie., counter-clockwise in the drawing) to generate the torque necessary to advance the reel toward the hub. Thus, in this instance, the drive pin 24 would wrap about the drive shaft 22 in a direction opposite to the direction of rotation “R₂” of the reel 10 on the drive shaft 22.

[0033] Thus, the apparatus of the present invention provides a means of winding or unwinding elongate material onto, or off of, a flanged reel in an efficient manner. To this end, the use of a clamp collar is eliminated while the safety and reliability is maintained. In addition, the ease of loading and unloading reels from the powered drive shaft is capable of being accomplished with semi or fully automated mechanisms (not shown). To this end, the reel can be pushed off the drive shaft 22 with automated equipment without requiring motorized rotation of the drive shaft 22. In this case, the shape of the drive pin 24 would cause the reel to rotate relative to the stationary drive pin and drive shaft as the reel is pushed out of engagement with the drive pin and off the free end of the drive shaft.

[0034] Many alternative configurations to that disclosed above can be utilized. For example, the drive pin can extend from the drive shaft instead of the hub, or the drive pin can extend from the flange of the reel and the corresponding aperture can be located in the hub of the winding/unwinding apparatus. The length of the drive pin can be modified as well as the extent to which it wraps about the drive shaft. In addition, the drive shaft can remain stationary while the reel is being rotated by the drive pin. Still further, the drive pin can abut the drive shaft 22 creating a drive shaft with a helical key which cooperatively engages a corresponding key way (ie., slot) which is provided in the flange of the reel and which is in communication with the central passageway 16.

DETAILED DESCRIPTION OF THE PREFERRED METHOD

[0035] The present invention also relates to a novel method of winding and/or unwinding elongate material onto, or from, a flanged reel 10. To this end, an empty reel is slid onto the drive shaft 22 for winding a length of material thereon, or a full reel is slid onto the drive shaft 22 for unwinding the material therefrom. In either case, the tip 24 a of the drive pin 24 is aligned and inserted into the aperture 18 located in the inboard flange 14 of the reel 10. At this point, there is no need to attach a collar clamp or like locking device on the free end 22 a of the drive shaft 22; rather, the free end 22 a of the drive shaft 22 is permitted to remain free.

[0036] In the case of a winding operation, an end of the elongate material is secured to a portion of the reel 10, such as to one of the end flanges 14, and the drive pin 24 is rotated relative to axis “A” to cause the reel 10 to rotate in the same direction about axis “A” thereby causing the material to be wound (ie., pulled) onto the reel 10 under a given amount of tension. Importantly, the drive pin 24 is a helix shaped drive pin, and the tension of the flaccid material generates a sufficient amount of torque on the reel 10 to cause it to be advanced further on the drive shaft 22 in a direction toward the hub 26 and to become further engaged on the drive pin 24. When the reel abuts the hub 26, the torque prevents the reel 10 from being displaced from the hub 26 and thereby prevents unwanted displacement off of the free end 22 a of the drive shaft 22.

[0037] After the winding operation is finished, the reel 10 is removed from the drive shaft 22 via its free end 22 a. The step of removing the reel 10 can be handled promptly and without delay since the free end 22 a of drive shaft 22 is not blocked by a clamp collar or like locking device.

[0038] An unwinding operation is handled similarly to that of a winding operation except for the force of pulling the flaccid material from the reel causes the reel 10 and drive pin 24 to rotate. The direction of rotation of the reel 10 about axis “A” and the direction in which the helix shaped drive pin 24 wraps about the drive shaft 22 is selected as previously discussed.

[0039] While a preferred apparatus, assembly and method have been described in detail, various modifications, alterations, and changes may be made without departing from the spirit and scope of the apparatus, assembly and method according to the present invention as defined in the appended claims. 

1. Apparatus for winding/unwinding elongate material onto/from a flanged reel, comprising: a substantially linear shaft for rotatably supporting the flanged reel; and a non-linear drive pin extending transversely of said shaft and rotatable about said shaft for rotating the flanged reel; whereby, when the flanged reel is supported on said shaft and is engaged by said drive pin and when said drive pin is rotated about an axis extending through said drive shaft, a torque is generated on the flanged reel by the tension of the elongate material being wound/unwound which causes the flanged reel to be urged onto said shaft and to prevent the flanged reel from being displaced from said shaft.
 2. Apparatus according to claim 1, wherein at least a portion of said drive pin has a helical shape which at least partially extends about said shaft.
 3. Apparatus according to claim 2, further comprising a hub from which said shaft and drive pin extend.
 4. Apparatus according to claim 3, further comprising a motor for rotating said hub, shaft, and drive pin.
 5. Apparatus according to claim 4, wherein said shaft defines a rotational axis about which said shaft is rotated in a pre-determined direction of rotation, wherein said helical-shaped portion of said drive pin includes at least a tip of said drive pin, and wherein, when said apparatus is utilized to wind material onto the flanged reel, said tip wraps at least partially about said shaft in a direction corresponding to said pre-determined direction of rotation of said shaft.
 6. Apparatus according to claim 4, wherein said shaft defines a rotational axis about which said shaft is rotated in a pre-determined direction of rotation, wherein said helical-shaped portion of said drive pin includes at least a tip of said drive pin, and wherein, when said apparatus is utilized to unwind material from the flanged reel, said tip wraps at least partially about said shaft in a direction corresponding to opposite said pre-determined direction of rotation of said shaft.
 7. An assembly for winding/unwinding elongate material, comprising a linear powered drive shaft extending from a hub and defining an axis of rotation; a flanged reel slidably supported on said drive shaft for rotation about said axis of rotation, said flanged reel having an inboard flange received on said drive shaft; and a drive pin extending from one of said hub and said inboard flange of said flanged reel and matingly engageable with a corresponding drive pin receiving channel located on an opposite one of said hub and said inboard flange so that, when said drive shaft is rotated about said axis, said flanged reel is caused to rotate about said axis and a torque is generated on said flanged reel to urge said flange reel in a direction onto said drive shaft and to prevent said flanged reel from being displaced from said drive shaft.
 8. An assembly according to claim 7, wherein at least a portion of said drive pin has a helical shape which at least partially wraps about said drive shaft.
 9. An assembly according to claim 8, wherein said drive pin extends from said hub and said drive pin receiving channel is located on said inboard flange of said flanged reel.
 10. An assembly according to claim 9, wherein said drive pin receiving channel extends parallel to said axis of rotation and has a diameter which is significantly larger than a diameter of said drive pin.
 11. An assembly according to claim 9, wherein said drive pin receiving channel has a shape corresponding to said drive pin and a diameter of a size similar to a diameter of said drive pin.
 12. An assembly according to claim 9, further comprising a motor for rotating said hub, drive shaft, and drive pin.
 13. An assembly according to claim 9, wherein said drive shaft rotates in a pre-determined direction of rotation about said axis, wherein said helical-shaped portion of said drive pin includes at least said tip of said drive pin, and wherein, when said assembly is utilized to wind the material onto said flanged reel, said tip wraps at least partially about said drive shaft in a direction corresponding to said pre-determined direction of rotation of said drive shaft.
 14. An assembly according to claim 9, wherein said drive shaft rotates in a pre-determined direction of rotation about said axis, wherein said helical-shaped portion of said drive pin includes at least said tip of said drive pin, and wherein, when said assembly is utilized to unwind the material from said flanged reel, said tip wraps at least partially about said drive shaft in a direction corresponding to opposite said pre-determined direction of rotation of said drive shaft.
 15. A method of winding/unwinding elongate material onto/from a flanged reel, comprising the steps of: sliding a flanged reel onto a linear shaft which extends from a hub, said flanged reel having an inboard flange relative to said hub and said inboard flange having a drive pin receiving channel; engaging at least a tip of a non-linear drive pin which extends from said hub beyond said channel of said inboard flange; rotating said non-linear drive pin about an axis extending through said linear drive shaft to perform one of a winding and unwinding operation; wherein, during said operation, the tension of the material generates a torque on said flanged reel to urge said flanged reel in a direction toward said hub and to prevent said flange reel from being displaced from said drive shaft.
 16. A method according to claim 15, wherein said rotating step includes rotating said drive pin in a pre-determined direction of rotation about said axis, wherein said drive pin has a shape substantially approximating a helical-shape, wherein said operation is a winding operation, and wherein said tip of said drive pin wraps at least partially about said drive shaft in a direction corresponding to said pre-determined direction of rotation.
 17. A method according to claim 15, wherein said rotating step includes rotating said drive pin in a pre-determined direction of rotation about said axis, wherein said drive pin has a shape substantially approximating a helical-shape, wherein said operation is an unwinding operation, and wherein said tip of said drive pin wraps at least partially about said drive shaft in a direction corresponding to opposite said pre-determined direction of rotation of said drive shaft.
 18. A method according to claim 15, wherein said step of engaging said drive pin with said channel includes engaging only said tip of said drive pin beyond said channel and thereby permitting the rotation of said drive pin and torque acting on said flanged reel to further advance said flanged reel onto drive shaft and into further engagement with said drive pin during said operation.
 19. A method according to claim 15, further comprising the step of removing said flanged reel from said drive shaft after said rotating step is completed, wherein said drive shaft has a free end opposite said hub which remains free during said rotating step to permit prompt removal of said flanged reel from said drive shaft after said rotating step.
 20. A method according to claim 19, wherein at least one of said steps of sliding a flanged reel onto said drive shaft and removing said flanged reel from said drive shaft are accomplished by an automated mechanism. 